Kotron® Sentinel Models 822, 832 and 842 Software Ver. 2.0D Integral Mount Software Ver. 2.0C Remote Mount Installation and Operating Manual RF Capacitance Point Level Switches Read this Manual Before Installing This manual provides information on the Kotron Models 822, 832 and 842 RF Point Level Switches. It is important that all instructions are read carefully and followed in sequence. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings. NOTES Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer. Cautions Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component’s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNINGS Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages The Kotron Model 822, 832 and 842 systems may be properly installed in Category II, Pollution Degree 2 installations. Follow all standard industry procedures for servicing electrical and computer equipment when working with or around high voltage. Always shut off the power supply before touching any components. Although high voltage is not present in this system, it may be present in other systems. Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety procedures when working with electrostatic sensitive components. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Low Voltage Directive For use in Category II installations. If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. Notice of Trademark, Copyright, and Limitations Magnetrol & Magnetrol logotype, STI & STI logotype, and Kotron are registered trademarks of Magnetrol International. Copyright © 2006 Magnetrol International All rights reserved. Performance specifications are effective with date of issue and are subject to change without notice. Magnetrol reserves the right to make changes to the product described in this manual at any time without notice. Magnetrol makes no warranty with respect to the accuracy of the information in this manual. Warranty All Magnetrol/STI electronic level and flow controls are warranted free of defects in materials or workmanship for one full year from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol/STI shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some Magnetrol/STI products. Quality Assurance The quality assurance system in place at Magnetrol/STI guarantees the highest level of quality throughout the company. Magnetrol/STI is committed to providing full customer satisfaction both in quality products and quality service. Magnetrol’s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches Table of Contents 1.0 Complete Installation 1.1 Unpacking ...........................................................1 1.2 Electrostatic Discharge (ESD) Handling Procedure...1 1.3 Before You Begin ...................................................2 1.3.1 Site Preparation ..........................................2 1.3.2 Equipment and Tools..................................2 1.3.3 Operational Considerations ........................2 1.4 Mounting ..............................................................3 1.4.1 Horizontal Mounting .................................4 1.4.2 Vertical Mounting.......................................4 1.5 Probe Installation ................................................. 5 1.5.1 Installing a Standard Probe .........................5 1.5.2 Installing a Flexible Probe...........................5 1.6 Installing a Remote Unit .......................................7 1.6.1 Main Amplifier...........................................7 1.6.2 Preamplifier ................................................7 1.6.3 Remote Wiring Connections ......................7 1.7 Wiring ..................................................................8 1.7.1 Relay Wiring ...............................................8 1.7.2 Power Wiring ..............................................8 1.7.3 Relay Wiring Chart .....................................9 2.0 Calibration 2.1 Operator Set Up..................................................10 2.2 Program Paths .....................................................11 2.3 Calibration – Single Point ...................................12 2.3.1 Program Path 1 – Configuration ...............12 2.3.2 Program Path 2 – Single Point ..................13 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2.4 Calibration – Multi Point....................................16 2.4.1 Program Path 1 – Configuration ...............16 2.4.2 Program Path 3 – Probe Calibration..........17 2.4.2.1 Probe Calibration Tips.......................18 2.4.2.2 Error Messages in PRLO/HI Menus................................................19 2.4.3 Program Path 4 – Multi-Point...................20 2.4.4 Program Path 5 – Service ..........................22 2.5 Advanced Calibration ..........................................24 2.5.1 Calibration with No Level Change ...........24 2.5.2 Tank Commissioning ................................24 2.5.2.1 Single Point .......................................24 2.5.2.2 Multi-Point........................................24 3.0 Reference Information ...............................................25 3.1 Troubleshooting...................................................25 3.1.1 Error Message Codes .................................25 3.2 Specifications.......................................................26 3.2.1 Electrical ...................................................26 3.3 Agency Approvals ................................................27 3.4 Intrinsic Safety.....................................................28 3.5 Specifications.......................................................30 3.5.1 Dimensional..............................................30 3.6 Parts ....................................................................33 3.6.1 Replacement .............................................33 3.7 Model Numbers ..................................................34 1.0 Complete 1.0 Complete Installation Installation This section provides detailed procedures for properly installing, configuring, and, as needed, troubleshooting Kotron Model 822, 832 and 842 Sentinel Point Level Switches. 1.1 Unpacking Unpack the instrument carefully. Make sure all components have been removed from the packing material. Check all the contents against the packing slip and report any discrepancies to the factory. Before proceeding with the installation, do the following: • Inspect all components for damage. Report any damage to the carrier within 24 hours. • Make sure the nameplate model number agrees with the packing slip and purchase order. • Record the model and serial numbers for future reference when ordering parts. 1.2 Electrostatic Discharge (ESD) Handling Procedure Magnetrol’s electronic instruments are manufactured to the highest quality standards. These instruments use electronic components that may be damaged by static electricity present in most work environments. The following steps are recommended to reduce the risk of component failure due to electrostatic discharge. • Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap the board in aluminum foil. Do not place boards on foam packing materials. • Use a grounding wrist strap when installing and removing circuit boards. A grounded workstation is recommended. • Handle circuit boards only by the edges. Do not touch components or connector pins. • Make sure that all electrical connections are completely made and none are partial or floating. Ground all equipment to a good, earth ground. 1 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 1.3 Before You Begin 1.3.1 Site Preparation Each Kotron Model 822, 832 and 842 switch is built to match the specific physical specifications of the required installation. Make sure the probe connection is correct for the threaded or flanged mounting on the vessel or tank where the switch will be placed. See Section 1.4, Mounting. Make sure that the wiring between the power supply and the Model 822, 832 or 842 switch is complete and correct for the type of installation. See Section 3.2, Specifications. When installing the Model 822, 832 or 842 switch in a general purpose or hazardous area, all local, state, and federal regulations and guidelines must be observed. See Section 1.7, Wiring. 1.3.2 Equipment and Tools No special equipment or tools are required to install the Model 822, 832 or 842 switch. The following items are recommended: • 11⁄8" open-end wrench or adjustable wrench to fit the probe process connection size and type. • Flat-blade screwdriver 1.3.3 Operational Considerations The Model 822, 832 or 842 switch should be located for easy access for service, configuration, and monitoring. There should be sufficient headroom to allow the probe to be inserted into the tank. Special precautions should be made to prevent exposure to corrosive atmosphere, excessive vibration, shock, or physical damage. The electronics should not be exposed to ambient temperatures above +160° F (+70° C) or below -40° F (-40° C). The proper operating temperature range for the display is -4° F (-20° C) to +160° F (+70° C). The temperature limits for the probe depend on the style and part number of the specific probe used. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2 1.4 Mounting The Model 822, 832 or 842 switch can be mounted to a tank using a variety of process connections. Generally, either a threaded or flanged connection is used. For information about the sizes and types of connections available, see Probe Brochure 50-125. Make sure all mounting connections are properly in place on the tank before installing the probe. Make sure the Kotron probe is correct for the intended installation. It is common practice to use the metal tank wall as the reference electrode. In such cases, it is required that the probe housing makes a good electrical connection to the tank wall. If there is any doubt about this connection or to the use of PTFE thread tape gaskets, paint, rust, or any other reason, a separate strap should be installed between the probe housing and the tank. Caution: This unit contains CMOS electronics which may be damaged by static electricity. Do not touch any semiconductor devices unless you are properly grounded. Caution: When a probe is used in an abrasive medium, inspect the probe periodically for visible surface wear. If damage to the probe insulation is found, replace the probe. Metal Walled Tanks On water-based liquids, there should be no problem with sensitivity or linearity. With non-conductive, low dielectric media, sensitivity can be enhanced by locating the probe close to and parallel with the tank wall. If this is not practical, a ground reference probe may be the solution. Non-Metallic and Glass-Lined Tanks With plastic, concrete, wood, or any other non-conductive walled vessels a ground reference is required. Most commonly, this electrode will be in the form of a concentric ground tube (i.e., stilling well). In questionable circumstances, consult the factory. In all cases, a good electrical connection must be made between the ground surface and the probe housing. Switch/Probe Assembly Switches with probes up to and including 12 inches (300 mm) in length are shipped pre-assembled. All other switches are shipped unassembled to avoid damage during transit. These transmitters must be assembled prior to mounting. Choose your particular configuration from the following sections and follow the instructions carefully. 3 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 1.4.1 Horizontal Mounting Alarm (narrow differential) applications only Figure 1 Recommended Horizontal Mounting Figure 2 Recommended Mounting with Nozzle Figure 3 Not recommended Figure 4 Recommended Horizontal Mounting Horizontally mounted probes provide a high degree of sensitivity for use with non-conductive liquids as only approximately 0.5 inches (12 mm) of level change is required to completely cover (or uncover) the probe. Horizontally mounted probes should be installed so that the probe is parallel to and at the level at which the control point is desired. Refer to Figure 1. Avoid any installation method in which the material may become trapped in the mounting nozzle, thus preventing the probe from signaling when the level recedes. Refer to Figures 2 and 3. NOTE: If nozzle mounting is unavoidable, the probe must be installed with an inactive metal sheath having a length of at least 1 inch (25 mm) greater than length of the nozzle. A sheath is required to render the length of the probe within nozzle insensitive to capacitance change. Refer to Figure 2. Guarded Probe Unit will signal at probe level. Refer to Figures 4 and 5. NOTE: The guard element must be located outside of the nozzle. Do not horizontally mount the unit in a nozzle deeper than 3 inches (75 mm). Refer to Figure 5. The medium may buildup in the nozzle and cause false activation. Alternate Horizontal Mounting On applications involving viscous liquids or materials which tend to cling or buildup, horizontally mounted probes should be installed at a slight downward angle to allow material to drain from probe rod. With this type of installation, the packing gland face of probe assembly should extend into the tank (or vessel). Refer to Figure 6. 1.4.2 Vertical Mounting Figure 5 Recommended Horizontal Mounting Vertically mounted probes provide the capability to adjust the control point up or down a section of probe rod by means of calibration adjustments within the unit. Vertically mounted probes should be installed so that the end of the probe rod is at least 2 inches (50 mm) below the lowest desired level control point with conductive materials or 4 inches (100 mm) below the lowest desired level control point with non-conductive materials. Refer to Figure 7 on page 5. Figure 6 Alternate Horizontal Mounting 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 4 1.5 Probe Installation NOTE: For units with remote electronics, the probe connections are made to the preamplifier. There is a two wire connection between the preamplifier and the main electronics. Refer to Section 1.6, Installing a Remote Unit, for details of installing the remote electronics. Follow Section 1.5, Probe Installation directions for details in installing the probe. 1.5.1 Installing a Standard Probe Figure 7 Vertical Mounting Before installing, ensure the: • Probe has adequate headroom for installation and has unobstructed entry in the vessel. 3871 ENT Probe (white) Guard (red) • Process temperature, pressure, dielectric, and viscosity are within the probe specifications for the installation. See Section 3.2, Specifications. To install a probe: 1. Thread probe into mounting bushing on tank. Apply wrench here 2. Tighten securely, being certain that the wrench is applied ONLY to the mounting gland. Refer to Figure 9. 3. Screw the amplifier housing onto the probe. Refer to Figure 9. Figure 8 Integral Mount with Guarded Probe 4. Screw housing on the probe until hand tight. Housing can be wrench tightened to align conduit connection with conduit. 5. Locate the white wire which is fastened to the probe terminal (P), Connect the free end of this wire to the probe connection screw. 3871 6. Proceed to Section 1.7, Wiring. ENT Probe (white) 1.5.2 Installing a Flexible Probe Caution: Insulated flexible probes are shipped with the cable clamp and the packing gland nut hand tightened. The end of a flexible probe MUST be kept taut by attaching the anchor end at the bottom of the vessel or by using a Magnetrol supplied probe weight. Caution: Do not discard the Mylar® housing insulator. Figure 9 Integral Mount with Standard Rigid Probe 5 Caution: The probe cable must not be in contact with any metallic surface in its final installation position. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches To install a probe: PROBE WIRE SCREW CLAMP MYLAR INSULATOR SET SCREW CLAMP RETAINING BUSHING 1. Attach the weight or anchor assembly to the end of the probe. Insert the probe through the vessel’s mounting connection, and feed the cable into the vessel. Do not allow the probe to scrape against the connection threads. 2. Secure the anchor assembly (if used), to the bottom of the vessel. UPPER MOUNTING NUT HALF 3. Apply thread sealant to the mounting nut. Screw the mounting nut into the mounting connection until tight. 4. Remove the Mylar housing insulator located over the clamp. DO NOT DISCARD. SEAL FLARE 5. Loosen both socket head screws from the clamp. Pull the clamp and Teflon® retaining bushing off of the probe. 6. While holding on to the probe cable, loosen the upper packing gland nut. DO NOT ALLOW THE PROBE CABLE TO FALL INTO THE VESSEL. LOWER MOUNTING NUT HALF 7. Pull the excess cable up through the packing gland nut until the cable is taut. Tighten the packing gland nut. PROBE CABLE 3/8-16-UNC-2B Figure 10 Integral Mount with Flexible Probe 8. Cut the cable 1.35" (34 mm) above the packing gland nut and strip off 1.25" (32 mm) of insulation. 9. Slide the Teflon® retaining bushing onto the cable and seat it into the packing gland nut. Slide the clamp onto the cable and seat it against the Teflon® retaining bushing. 10. Tighten both socket head screws, on the clamp, to approximately 35 in/lbs of torque. Slip the Mylar® insulator over the clamp. Caution: Check probe terminal connection carefully to be certain lug will not short to packing gland or interfere with assembly of amplifier housing to probe. 11. Locate the white wire which is fastened to the probe terminal (P), Connect the free end of this wire to the probe connection screw. 12. Proceed to Section 1.7, Wiring. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 6 1.6 Installing a Remote Unit NOTE: Units with remote electronics are provided with the Main Amplifier and a preamplifier. Probe connections are made to the preamplifier. Refer to Section 1.5, Probe Installation for details in installing the probe. 3871 1.6.1 Main Amplifier ENT + (Red) – (Black) Probe (white) Shield Side V Preamp G Side View Main Amplifier P Q4 U2 Q1 + (Red) Probe (white U4 Q3 U5 – (Black) Shield cut back and taped Top View Preamplifier Figure 11 Remote Electronics with Standard Rigid or Flexible Probe Remote amplifier assemblies are normally shipped from the factory assembled into an “L” mounting bracket. Install bracket in a location that will isolate the unit from temperatures below -40° F (-40° C) and over +160° F (+70° C) or vibration/mechanical damage. Unit can be mounted up to 2500 feet (760 m) from probe assembly. Intrinsically safe models can be mounted up to 800 feet (240 m) from probe assembly. Location should also offer easy access for wiring, calibration, and maintenance. 1.6.2 Preamplifier 1. Screw the preamplifier housing onto the probe until hand tight. Housing can be wrench tightened to align conduit connection with conduit. 2. Attach white wire from the probe to the connection on the preamplifier – see Figure 11. 3. If using a guarded probe, attach the red wire from the probe to the connection on preamplifier – see Figure 12. 3871 1.6.3 Remote Wiring Connections ENT + (Red) – (Black) Guard (red) Probe (white) Shield To connect preamplifier-to-amplifier, use shielded, twisted pair, 22-gauge stranded connectors (part number 09-7146-001). 1. Strip approximately 0.4 inch (10 mm) of outer jacket insulation from each end of the shielded, twisted-pair. Side View Preamplifier Side View Main Amplifier G Q4 Guard (red) P Q1 Probe (white) U4 Q3 U2 U5 + (Red) Top View Preamplifier – (Black) Shield cut back and taped 2. At the probe preamplifier end, cut the bare shield wire of the cable close to the insulating jacket. 3. Connect the red lead to the positive (+) terminal on the amplifier. Refer to Figure 11 or 12. 4. Connect the black lead to the negative (–) terminal on the preamplifier board. 5. Connect the red lead to positive (+) terminal on the amplifier. Figure 12 Remote Electronics with Guarded Probe 6. Connect black lead to the negative (–) terminal on the amplifier. 7. Connect the shield to the ground ( amplifier. 7 ) terminal on the 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 1.7 Wiring WARNING! Explosion hazard. Do not disconnect equipment unless power has been switched off or the area is known to be safe. 1.7.1 Relay Wiring The recommended connection of power and control circuits is 16 AWG or 18 AWG stranded wire. D4 D3 Q3 TB3 RL3 Q4 Q2 NC R4 R3 R1 R2 C NO C TB3 NO D5 RL4 RL2 C2 VR1 NC NC C C NO NO 8 P1 1 TB4 TB2 NO C NC NO C NC D2 TB4 TB2 TB1 NO C NC NO C NC Q1 TB1 NC C NO NC C NO RL1 NC C NO NC C NO NC Z1 F2 To improve external noise immunity, electrical snubbers are provided on the relay contacts. These are factory installed between the common (C) and the normally open (NO) contacts. The position of the snubbers should be changed between the C and NC contacts if the normally closed (NC) contacts are used. NOTE: If the snubbers are not wired properly in parallel with the relay contacts, external electrical noise may disturb the operation of the instrument. + C4 8 J6 1 J8 F1 C3 R8 J7 T1 J2 1/8 AMP SLO-BLO Refer to Section 1.7.3, Relay Wiring Chart for different relay wiring options. Refer to Figure 13 for terminal locations. J3 J9 R7 R5 VR3 5 J5 4 J1 R6 NOTES: 1. Relay 2 and relay 3 can be utilized for lead-lag pump sequencing (models 832 and 842 only). + - + VR2 C1 D1 J4 BR1 -+ H TB5 N Figure 13 2. Relay 1 can be utilized as a dedicated diagnostic alarm. Refer to Calibration sections (pages 10–23) for proper use of these relays. 1.7.2 Power Wiring 1. Ensure that power source is turned off. 2. Pull power supply wires through conduit connection. 3. Connect the positive supply wire to the H terminal, and the negative (neutral) supply wire to the N terminal. Connect the ground wire to the green ground screw in the bottom of the housing. 4. Dress the wires together neatly and secure with cable ties. Be certain that adequate clearance exists for replacement of housing cover NOTE: Observe all applicable electrical codes and proper wiring procedures. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 8 5. Replace housing cover. 6. Apply power to the unit, and proceed with calibration of instrument as described in Section 2.0, Calibration beginning on page 10. NOTE: Be certain to route all power and control wires through conduit outlet only and run probe wire up through center hole in amplifier housing base. 1.7.3 Relay Wiring Chart Kotron Power Material Level Relay Terminals CM to NC CM to NO Fail-safe Relay Coil HLFS LLFS HLFS LLFS De-energized Energized Energized De-energized Closed Open Open Closed Open Closed Closed Open HLFS LLFS HLFS LLFS De-energized De-energized De-energized De-energized Closed Closed Closed Closed Open Open Open Open High On Low High Fail Low NOTES AND DEFINITIONS: 1. Equipment controlled by the Kotron relays is assumed to be powered from one source, while the Kotron unit itself is assumed to be powered from a different source. 2. Fail means a loss of power to the Kotron unit. 3. HLFS (high level fail-safe) means a material level in the tank which is equal to or above: a. The setting of a narrow differential point. b. The higher setting of a wide differential point. 4. LLFS (low level fail-safe) means a material level in the tank which is equal to or below: a. The setting of a narrow differential point. b. The lower setting of a wide differential point. 5. a. When the relay coil is de-energized, a connection is made between terminals C (common) and NC (normally closed), and there is no connection between C and NO (normally open). b. When the relay coil is energized, a connection is made between terminals C and NO, and there is no connection between C and NC. 6. If Relay 1 is being used as a dedicated diagnostic alarm, the relay will always de-energize upon fault detection. 9 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2.0 Calibration 2.1 Operator Set Up MagneCal™, the Sentinel’s sophisticated calibration software, uses a microprocessor-based user interface, which provides the operator unmatched flexibility and programmability for a variety of level control applications. These features are built into the controller and are entered via three tactilearrow, DOWN arrow, and feedback keys (UP ENT ) located on the amplifier circuit board. In addition, a 4-digit LED displays the operating parameters and values. The keys and their functions are shown below. ENT Upon power up, the LED will display the following message: Magnetrol Int’l followed by a series of walking M’s (multi-point) or S’s (single point), based on the calibration configuration selected. This is the normal RUN mode. UP/RAISE: Use to scroll up through menu selections, or raise numeric values. There are three speeds for scrolling numeric values. Ramp speed is increased by continuously arrow key. To decrease speed as the depressing the UP arrow key desired value is approached, release the UP and unit will revert to the slowest ramp speed. DOWN/LOWER: Use to scroll down through menu selections or lower numeric values. There are three speeds for scrolling numeric values. Ramp speed is increased by arrow key. To continuously depressing the DOWN decrease speed as the desired value is approached, release arrow key and the unit will revert to the DOWN slowest ramp speed. ENT ENTER: Use to select displayed value and to continue to the next menu selection. Complete menu layouts are provided to show the user-selectable parameters. NOTE: The unit will automatically time out and revert to the RUN mode after 60 seconds of no key strokes. Any information already entered is secure, and the calibration may be safely resumed at any time. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 10 The microprocessor-based Sentinel offers all operator functions and setup procedures from the three tactile-feedback keys described above. Due to the number of user programmable features included in the unit, the calibration flow chart is extensive. The flow chart is modular, however, it can be divided into five subsections or program paths which are connected to a home base, or normal operating mode, RUN (walking M or S). When letters scroll horizontally across the LED and no error messages are displayed, all systems are functioning properly. The calibration flow chart structure is shown on page 12. NOTE: If MagneCal precalibration data was entered at the factory, use Advanced Calibration procedures (Section 2.5) in conjunction with the standard calibration procedures. 2.2 In order to properly calibrate the Sentinel, the Calibration instructions are broken down into the five PATHS described below. Access to program paths is granted with the following key strokes: Configuration Single Point Service R U N Program Paths Configuration and UP Press ENT simultaneously ( ) ENT Probe Calibration arrow keys ENT Single Point Press ENT ENT Multi-Point Probe Calibration Press UP and DOWN simultaneously ( ) arrow keys NOTE: This procedure MUST be performed if Multi-Point mode is selected. Multi-Point Press ENT ENT Service Press ENT and DOWN simultaneously ( ) ENT arrow keys ENT NOTE: At any given time during user configuration, pressing the ENT , UP , and DOWN arrow keys simultaneously ( ) will escape from any location and return to RUN. ENT ENT 11 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2.3 Calibration—Single Point 2.3.1 Program Path 1 — Configuration The SING (single point) program is for single point alarm applications and allows for proper calibration without level change. The MULT (multi-point) program is for all pump (wide differential) control, multiple relay applications, and single point applications where an adjustable set point is needed. NOTE: Specific order of the configuration modes must be followed for proper calibration of the Sentinel Level Switch. It is imperative that the user select CONFIGURATION for the first calibration procedure. Within the CONFIGURATION mode, the single or multi-point operation must be selected. This selection affects the balance of the configuration procedures and will signifiRUN cantly affect the performance of the level switch if the modes of operation are not followed. ENT CNFG STEP 1: CNFG (Configuration) ENT 1. From the RUN mode, press the ENT and the UP arrow key simultaneously ( ) to enter the menu. The display will read CNFG. Configuration is the first mode in configuring the Sentinel. (Refer to the previous NOTE). ENT OFF COMM ENT TERM HOST ADDR ENT MODE to confirm configuration selection and unit 2. Press ENT will display COMM. COMM (Communications) refers to a future RS-485 option of the Sentinel. Although selections appear in the flowchart (screened area) and in the software program, these features are not available at this time. ENT ENT MULT ENT SING Calibration Flow Structure to display MODE. 3. With COMM displayed, press DOWN STEP 2: MODE (Mode) 1. Mode refers to the selection of a single point (alarm only) or multi-point a (pump control) application of the to display MULT. Sentinel. Press ENT ENT 2. Since single point use is desired, using the UP or DOWN arrow keys, toggle between single or multipoint selection. 3. Once SING is displayed, press ENT RUN mode. ENT to return to the NOTE: Upon SING (single point) selection and the return to the RUN mode, the display will verify your selection by displaying a walking S (single point mode). Proceed to Section 2.3.2, Program Path 2 — Single Point. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 12 2.3.2 Program Path 2 — Single Point The single point program is for single point, alarm only applications and allows for proper calibration without level change. The following procedures must be followed if SING (single point) has been selected in Program Path 1 CNFG (configuration). When in need of an adjustable set point (vertical probe only), use MULT (multi-point). From the RUN display, press ENT ENT RUN ENT STEP 1 LEVL . STEP 1: LEVL (Level) 1. From the RUN mode, press the ENT key to enter this menu. The display will read LEVL. LEVL refers to the condition of the probe DRY (not covered with media) or WET (covered with media). ENT DRY ENT ENT WET ENT STEP 2 MDIA NONC ENT COND ENT STEP 3 PRBE BARE ENT STEP 4 TDLO INS 2. Press ENT ENT to display DRY. and DOWN arrow keys, toggle 3. Using the UP between DRY and WET until the display reads the current condition of the probe. 4. Press ENT MDIA. ENT to store this value. The display will read STEP 2: MDIA (Media) 1. MDIA (media) refers to the conductance n(dielectric) of to display NONC the process media. Press ENT (non-conductive). ENT and DOWN arrow keys, toggle 2. Using the UP between NONC (non-conductive) and COND (conductive) until the display reads the appropriate condition of the media. 3. Press ENT ENT to store this value. The display reads PRBE. NOTES: 1. This procedure sets the sensitivity appropriate for the application: NONC = 0.5 pF COND = 10 pF. 2. If the conductance of the medium is unknown, choose NONC (non-conductive) for greatest sensitivity. 3. When calibrating for media in non-metallic (ungrounded) vessels, choose NONC (non-conductive). This will establish the highest sensitivity (0.5 pF). STEP 3: PRBE (Probe) 1. PRBE (probe) selects either an insulated or bare probe. to display BARE. When PRBE is displayed, press ENT ENT 2. If this is the type of probe in use, press ENT Step 4, TDLO will be displayed. 13 ENT . 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 3. If not, using the UP and DOWN arrow keys, toggle between the INS (insulated) and the BARE (bare) probe selections. 4. When the appropriate selection is displayed, press ENT to store the value and to display TDLO. ENT NOTE: Choice of MDIA/COND and PRBE/BARE disarms the shorted probe diagnostic check. STEP 4: TDLO (Time Delay Low) 1. TDLO (time delay low) selects the desired setting of time delay on falling level. When TDLO is displayed, press ENT to display current value. ENT ENT STEP 4 TDLO XXXX ENT ENT STEP 5 TDHI XXXX ENT ENT STEP 6 FLSF LLFS ENT STEP 7 FALT HLFS 2. Using the UP or DOWN push-buttons, scroll up or down to achieve the desired numeric value of the time delay low. Time delay is adjustable between 0 and 90 seconds (one second is recommended). 3. When the appropriate value is displayed, press ENT store the value and to display TDHI. ENT to STEP 5: TDHI (Time Delay High) 1. TDHI (time delay high) selects the desired setting of time delay on rising level. When TDHI is displayed, press ENT to display current value. ENT 2. Using the UP or DOWN arrow keys, scroll up or down to achieve the desired numeric value of the time delay high. Time delay is adjustable between 0 and 90 seconds (one second is recommended). 3. When the appropriate value is displayed, press ENT store the value and to display FLSF. ENT to STEP 6: FLSF (Fail-safe) 1. FLSF (fail-safe) selects either a low level or high level fail-safe condition (relay is energized when not in alarm and de-energized when alarmed). When FLSF is disto display LLFS. played, press ENT ENT 2. If this is the desired condition, press ENT will be displayed. ENT and FALT 3. If HLFS is desired, use the UP or DOWN arrow keys to toggle between the selections. 4. When the appropriate selection is displayed, press ENT to store the value and display FALT. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches ENT 14 STEP 7: FALT (Fault) 1. FALT (fault) refers to the choice of the alarm relay to DNRG (de-energize) or IGNR (ignore) upon diagnosing a fault. ENT STEP 7 FALT DNRG NOTE: The dedicated diagnostic Relay 1 will always de-energize when a fault is detected. IGNR ENT ENT STEP 8 CAL ENT NO When FALT is displayed, press ENT ENT to display DNRG. 2. If this is the desired condition, press ENT CAL. YES ENT to display ENT 3. If IGNR is desired, use the UP or DOWN arrow key to toggle between the selections. 4. When the appropriate selection is displayed, press ENT to lock in the value and display CAL. ENT STEP 8: CAL (Calibration) 1. After modifying any or all of the preceding values, CAL will lock in all the values and store them in memory. Press ENT to display NO (do not calibrate). ENT 2. Press ENT ENT if it is desired to leave current values. 3. If new values are desired, use the UP and DOWN arrow keys to toggle to YES (calibrate). 4. Press ENT to lock all the new values in memory and return to the RUN mode. ENT NOTE: Ensure that the level of the process media is at the exact point that corresponds to the choice made in Step 1 LEVL:DRY (not covered with media) or WET (covered with media). This is critical to the proper calibration of the instrument. The unit will take a new capacitance reading (establish a new set point) when YES is chosen and ENT is depressed. ENT 15 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2.4 Calibration—Multi Point 2.4.1 Program Path 1 — Configuration The SING (single point) program is for single point alarm applications and allows for proper calibration without level change. The MULT (multi-point) program is for all pump (wide differential) control, multiple relay applications, and single point applications where an adjustable set point is needed. NOTE: Specific order of the configuration modes must be followed for proper calibration of the Sentinel Level Switch. It is imperative that the user select CNFG for the first calibration procedure. Within the CNFG mode, the single or multi-point operation must be selected. This selection affects the balance of the configuration procedures and will significantly affect the RUN performance of the level switch if the modes of operation are not followed. ENT CNFG ENT STEP 1: CNFG (Configuration) OFF COMM 1. From the RUN mode, press the ENT and the UP arrow keys simultaneously ( ) to enter the menu. The display will read CNFG. Configuration is the first mode in configuring the Sentinel. (Refer to the NOTE above). ENT TERM ENT HOST ADDR ENT MODE ENT ENT MULT ENT SING to confirm configuration selection and unit 2. Press ENT will display COMM. COMM (Communications) refers to a future RS-485 option of the Sentinel. Although selections appear in the flowchart (screened area of diagram at left) and in the software program, these features are not available at this time. 3. With COMM displayed, press the DOWN display MODE. arrow key to STEP 2: MODE (Mode) 1. MODE refers to the selection of a single point (alarm only) or multi-point application of the Sentinel. Press ENT to display MULT. ENT 2. Since multi-point use is desired, press ENT the RUN mode. ENT to return to For MULT (multi-point) selection, the display will read **NOT READY**. Proceed to Section 2.4.2, Program Path 3 — Probe Calibration. NOTE: Although standard procedure is to calibrate the probe first (eliminating the **NOT READY** message), relay parameters can be set prior to calibrating the probe. This means full calibration of all relays may be done indoors on a test bench. The remaining PRLO/PRHI points can then be calibrated, after the unit is installed. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 16 2.4.2 Program Path 3 — Probe Calibration RUN ENT PRHI ENT ENT NOTES: 1. The media level must be moved to accomplish this procedure. The PRLO and PRHI points may be entered in any order; they can easily be changed in the future when the process level is at a much higher or lower point. 2. The unit will automatically time out and revert to the RUN mode after 60 seconds without a keystroke; any information already entered remains in memory. To enter any remaining data, simply re-enter the Probe Calibration section. 3. A minimum level change of 2% or 5pF, whichever is greater, of tank height will yield a valid calibration. However, a greater XXXX level change yields better accuracy. ENT ENT REVW PRLO XXXX ENT PRHI ENT ENT XXXX ENT ENT CAL PRLO XXXX STEP 1: REVW (Review) This menu allows the review of any previously stored PRLO/PRHI points. If this is the first time calibration is performed, proceed to Step 2. 1. To enter this menu from the RUN mode, press the UP and DOWN arrow keys simultaneously. ( ) The display will read REVW (review). 2. Press ENT ENT to display PRLO (probe low). 3. Press ENT to display the previously stored PRLO point. ENT 4. Press ENT ENT to display PRHI. 5. Press ENT to display the previously stored PRHI point. ENT 6. Press ENT ENT to display PRLO. 7. Press the DOWN arrow to return to the main path. The display will read CAL. NOTE: If re-entering new PRLO/PRHI points for better accuracy, be sure that the new PRLO point is lower than the existing PRLO point and the new PRHI point is higher than the existing PRHI point. STEP 2: CAL (Calibrate) This menu allows the calibration of the Probe. Caution: This is the most critical section of the calibration procedure. Before pressing ENT to enter data into the PRLO or PRHI areas, be sure it is the proper area needed at that point. If an improper area is entered, pressing all three buttons simultaneously will return you to the RUN mode. ENT 1. To enter this menu, press ENT read PRLO (probe low). 17 ENT . The display will 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2. If the PRLO point is to be calibrated, press ENT to display the present value. ENT arrow key to scroll to the exact level of 3. Use the UP the media, in any unit of measurement (inches, feet, percentage, etc.), being consistent to use the same unit of measurement throughout theprocedure. 4. Once the exact unit is reached on the display, press ENT to store the information in memory. The display will read PRHI (probe high). Raise the process level to a PRHI calibration point. ENT NOTE: If entering different PRLO/PRHI points for greater accuracy, be sure that the new PRLO point is lower than the existing PRLO point and the new PRHI point is higher than the existing PRHI point. 5. Press ENT to display the present value. Scroll to the to store the exact level of the media and press ENT information in memory. The display will read PRLO once again. ENT ENT arrow key to leave the CAL mode 6. Press the UP and return to the RUN mode, MAGNETROL INTL M M M. Probe calibration is complete. Proceed to Section 2.4.3, Program Path 4 — Multi-Point. 2.4.2.1 Probe Calibration Tips If you mistakenly get into the wrong area of the program (for instance, PRLO data when PRHI data was intended), remember, pressing all the three tactile feedback keys arrows) simultaneously will (ENT/UP/DOWN return you to the RUN mode. ENT After establishing the probe low point (and the unit times out from the CAL mode to the RUN mode while raising the level for the probe high point), DO NOT press ENT after returning to the CAL mode when PRLO arrow key to bypass PRLO and appears. Press the UP obtain PRHI. This will avoid setting the PRLO point where the PRHI point should be. ENT If you get lost, and the unit continually displays ERROR messages (2LO or 2HI, etc.), do the following: 1. Return to the RUN mode by pressing the DOWN arrow (from PRHI). (from PRLO) or the UP arrow 2. From the RUN mode, press the ENT and the UP arrow keys simultaneously ( ) to enter the menu. The display will read CNFG. ENT ENT 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 18 3. Press the DOWN ENT . arrow key to get to MODE. Press ENT 4. Scroll to SING. Press ENT . Unit reads NOT READY. You are now in the Single Point Mode. ENT 5. Return to CNFG and repeat the above procedure now choose MULT from the MODE menu. Press ENT . Unit reads MAGNETROL INTL M M M…. ENT 6. All of the original data has now been cleared. 7. Begin Probe Calibration procedure again from the start of Program Path 3 (page 17). 2.4.2.2 Error Messages in PRLO/HI Menus 1. 2BIG: Occurs during PRLO or PRHI data entry when displayed value exceeds 19999. 2. 2SML: Occurs during PRLO data entry when displayed value underflows 0, or during PRHI when displayed value underflows 1. 3. 2 LO: Occurs when stored PRHI measurement (not display) would be less than currently stored PRLO measurement. In other words, the capacitance being used to set the PRHI point is less than the capacitance used to set the PRLO. Probe high Probe low Figure 14 4. 2 HI: Occurs when stored PRLO measurement (not display) would be more than currently stored PRHI measurement. In other words, the capacitance being used to set the PRLO point is more than the capacitance used to set the PRHI point. 5. UNDR: Occurs when displayed value goes below -999. 6. OVER: Occurs when displayed value goes above 19,999 (red, >10,000 LED illuminated and 9999 on the display). 19 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2.4.3 Program Path 4 — Multi-Point RUN ENT ENT ENT DISP XXXX MODE CNTL ENT NORM LEAD ENT The following procedure must be follower if MULT (multi-point) has been selected in Program Path 1 CNFG (configuration). Probe calibration, Program Path 2, must also be accomplished for the Multi-Point program to operate. These two procedures, Multi-Point and Probe Calibration, can be done in any order. NOTE: Use the same unit of measure that was used in Probe Calibration. Be consistent throughout the program. Press ENT to read DISP. Press the DOWN key to display MODE. arrow ENT ENT DNRG FALT STEP 1: DISP (Display) IGNR 1. Press ENT to read DISP. The display will read the actual process level, based on the unit of measure that was used in Probe Calibration (PRLO/PRHI). ENT ENT RLY1 FALT LVLO XXXX ENT 2. Press the DOWN ENT LVHI SET ENT KILL ENT arrow key to display MODE. XXXX TDLO STEP 2: MODE (Mode) XXXX TDHI 1. MODE refers to the configuration of both the control to display CNTL mode and the fault mode. Press ENT (control). Control allows for selection of normal or lead-lag pump control. ENT ENT XXXX ENT 2. If this is the desired condition, press ENT ENT LLFS ENT HLFS RLY2 ENT . 3. The next level of the menu will be displayed; the selection of normal or lead-lag pump control. Choosing NORM will allow normal operation of the relays. If lead-lag pump arrow key to sequencing is desired, press the DOWN display LEAD. NOTE: Selection of LEAD (lead-lag) affects relays 2 and 3 only and does not apply to Model 822. LEAD must NOT be selected for Model 822. 4. Once the proper choice is displayed, press ENT to display FALT. to display DNRG (de-energize). In this 5. Press ENT position, all control relays will de-energize (go to a fail-safe state) when a fault is diagnosed. or DOWN arrow keys to toggle 6. Use the UP between DNRG (de-energize) or IGNR (ignore). If IGNR is chosen, all control relays will continue operating when a fault is diagnosed. to store the appropriate choice. The unit 7. Press ENT reads RLY1. ENT ENT ENT 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 20 STEP 3: RLY1 (Relay 1) 1. With RLY1 displayed, press ENT to display FALT. In this setting, the RLY1 is used as a dedicated, diagnostic alarm. No other relay parameters (i.e., LVLO, TDHI) are offered. The relay will now de-energize when a diagnostic problem is encountered. ENT RUN ENT RLY2 SET LVLO ENT XXXX ENT LVHI KILL XXXX ENT TDLO XXXX ENT TDHI XXXX ENT arrow key to toggle 2. For other choices, use the DOWN to KILL. In this setting, the relay is removed from service. The process level may be varied (the display and the yellow LEDs will respond), but the relay will not change state and affect equipment (pump, valve, etc.) which is connected to it. The relay will remain in a de-energized state. or 3. For the standard operating position, press the UP DOWN arrow keys to display SET. Relays will respond to calibrated settings. (All relay parameters can be entered from either KILL or SET). to 4. When the desired setting is displayed, press ENT lock in the value and to display LVLO (low trip point). ENT ENT LLFS ENT HLFS RLY3 Same as RLY2 5. Press ENT ENT 6. Use the UP the value. to display the current value. or DOWN arrow key to raise or lower 7. When the desired setting is displayed, press ENT lock in the value and display LVHI. ENT to 8. Press ENT once again to display the current value for LVHI (high trip point). ENT RLY4 Same as RLY2 9. Use the UP the value. or DOWN arrow key to raise or lower 10. When the desired setting is displayed, press ENT to lock in the value and display TDLO (time delay low). ENT 11. Press ENT once again to display the current value for TDLO. Time delay low selects the desired value of time delay on falling level. ENT or DOWN arrow key to raise or 12. Use the UP lower the value. Time delay is adjustable between 0 and 90 seconds. to lock 13. When the desired value is displayed, press ENT in the value and to display TDHI (time delay high). ENT 14. Press ENT once again to display the current value of TDHI. Time delay high selects the desired value of time delay on rising level. ENT 21 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 15. Use the UP or DOWN arrow key to raise or lower the value. Time delay is adjustable between 0 and 90 seconds. to lock 16. When the desired value is displayed, press ENT in the value and to display LLFS (low level fail-safe). ENT 17. If LLFS is the required condition, press ENT display RLY1. ENT to 18 If high level fail-safe is desired, use the UP or DOWN arrow key to toggle to HLFS. When the desired condito display RLY1. Refer to tion is displayed, press ENT Section 1.7.3, Relay Wiring Chart for fail-safe information. ENT arrow key to proceed to RLY2. 19. Press DOWN NOTE: If relay is used as an alarm, and differential is set to zero (i.e., LVLO = 14 and LVHI = 14), a small amount of time delay is recommended (usually one second). NOTE: Relays 2, 3, and 4 are configured in the same manner as Relay 1, except that the fault condition is not an option. 2.4.4 Program Path 5 — Service From the RUN display, press the ENT arrow keys simultaneously. ENT and DOWN ENT RUN SERV ENT ENT VERS The Service program path is designed to aid the customer in troubleshooting the Sentinel; it should be accessed only with the assistance from Magnetrol factory personnel. Only the TEST mode section may be utilized without factory assistance. ENT XXXX STEP 1: SRVC (Service) XXXX From the RUN Mode, press the ENT and DOWN arrow keys simultaneously. ( ) The display will read SRVC. ENT ENT ENT HEX ENT AVG STEP 2: VERS (Version) ENT ENT Press ENT XXXX ENT to display VERS (version). again to display the current software Press ENT revision number. ENT ENT ENT TEST ENT TRIP XXXX ENT HOLD Press ENT ENT to display SRVC once again. Press ENT ENT to display VERS. Use the DOWN (hexadecimal). arrow key to display HEX Multiple Mode Only 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 22 STEP 3: HEX (Hexadecimal) Press ENT . Display will show a hexadecimal number related to capacitance in 0.25 pF increments. ENT Press ENT ENT to exit HEX and return to SRVC. Press ENT ENT again to display VERS. Using the DOWN display AVG. arrow key, press two times to STEP 4: AVG (Average) Press ENT to display a number (0–5) related to the amount of averaging of the probe signal the microprocessor does to yield a level value. A value of 0 is the minimum averaging value; 5 is the maximum averaging value. All units are shipped from the factory with a preset averaging value of 3. ENT NOTE: Consult factory before changing this value. Press ENT , with the averaging value displayed, to return to SRVC. ENT Press ENT ENT again to display VERS. Using the DOWN to display TEST. arrow key, press it three times STEP 5: TEST (Test) The test mode allows manual scrolling of the process level via the keypad and LED display. This checks all relay settings artificially. to display TRIP. Relays will change Press ENT state (trip) at the calibrated points. ENT or DOWN arrow keys to toggle to Use the UP HOLD. In this setting, relays will not change state (hold) at the selected points, but the yellow LEDs will still signal as normal (OFF when below lowest differential point; blinking when inside differential; and ON when above highest differential point). Press ENT ENT Use the UP ENT ENT to display the present level. arrow key to scroll through values. will escape TEST and display SRVC. With SRVC displayed, press the UP key to return to RUN. arrow NOTES: 1. The TEST mode will not operate until PRLO and PRHI values are entered in Probe Calibration (Program Path 3). 2. There is no TEST mode for the single point program. 23 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 2.5 Advanced Calibration Use these procedures in conjunction with standard calibration procedures already observed. 2.5.1 Calibration with No Level Change 1. Single Point: Accomplished in Section 2.3.2, Program Path 2 — Single Point procedure. 2.5.2 Tank Commissioning Initial calibration in water (conductive medium) with final use in a non-conducive medium. If final medium is also conductive, no calibration change is necessary 2.5.2.1 Single Point 1. Water (commissioning medium): Follow standard calibration procedure. 2. Final Process Medium (non-conductive): In Single Point program, change MDIA (media) from COND (conductive) to NONC (non-conductive) 2.5.2.2 Multi-Point NOTE: Proper probe choice is critical. If final medium is conductive (i.e., dielectric is >10 or conductivity is >10 micro mho/cm), any insulated probe may be utilized. If final medium is nonconductive (i.e., dielectric is <10 or conductivity is <10 micro mho/cm), an insulated stilling well probe must be utilized (models 8XA-XAXB-XXX or 8XB-AAXB-XXX). 1. Water a. Establish PRLO point (refer to Section 2.4.2, Program Path 3 – Probe Calibration). With probe installed and NO liquid in the vessel, enter PRLO point. This value should equal the distance of the tip of the probe from the bottom of the vessel, plus one inch. b. Establish PRHI point (refer to Section 2.4.2, Program Path 3 – Probe Calibration). Raise level of the commissioning liquid (usually water) to the highest point possible. Enter PRHI point. c. Complete relay calibration (refer to Section 2.4.2, Program Path 3 – Probe Calibration). 2. Final Process Medium With commissioning liquid removed and final process medium in the vessel, reestablish PRHI point (for best results at least 25% of the probe should be immersed). Relay control parameters are now calibrated to the new process medium. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 24 3.0 Reference Information 3.1 Troubleshooting 3.1.1 Error Message Codes The following error messages are displayed to aid the user in troubleshooting the system. Many of the error messages relate to data stored in the non-volatile memory. Error messages 11, 12, 13, and 16 can be investigated by the user. Consult factory for all other failures. Symptom Problem Solution Error Message 1 (ER1) Relay 1: Error in stored data Consult factory. Error Message 2 (ER2) Relay 2: Error in stored data Consult factory. Error Message 3 (ER3) Relay 3: Error in stored data Consult factory. Error Message 4 (ER4) Relay 4: Error in stored data Consult factory. Error Message 5 (ER5) Relay configuration: lead-lag, Fail-safe Consult factory. Error Message 6 (ER6) Average/filtering Consult factory. Error Message 7 (ER7) Probe Hi/Probe Lo calibration error Consult factory. Error Message 8 (ER8) Computation error based on E7 Consult factory. Error Message 9 (ER9) Parameter error in power up Consult factory. Error Message 10 (ER10) Not applicable Not Applicable. Preamplifier Test Integral: consult factory. Remote: measure current on the positive (+) side of circuit, between preamplifier and main amplifier; 30 to 40 mA is proper. Probe Short Test Disconnect the probe wire from the probe. Measure the resistance between the probe connection screw and the metal probe mounting nut; use the highest resistance scale available. A reading of 10 megohm or greater (and stable) is proper. Error Message 11 (ER11) Error Message 12 (ER12) NOTE: If the application is an insulated probe in a conductive medium, it helps to have the process level at the highest point possible. This aids in checking for nick or cuts in the probe insulation. Error Message 13 (ER13) Open probe circuit Check wiring between electronics and probe. Error Message 16 (ER16) Immeasurable signal – No wave form beyond maximum capacitance capability. Integral: Consult factory. Remote: Perform checks described under Error Messages 11, 12, and 13. Display reads “NOT READY” PR LO/PR HI points not calibrated Calibrate probe Program Path 3 Calibration The LED display defaults to Magnetrol Intl when a relay trips. Noise from relay (and related equipment) is causing problems with microprocessor. Install filtering device 9i.e., MOVs) across relay terminals and supply voltage input. The S or M stops walking across LED The 8-pin header between the two circuit display, yet no error message appears. boards is not making good contact. Probe totally shorted. Supply power between 19-21 VDC Review solution for ER 12. Check supply power. Diagnostic relay trips every time the process level trips the alarm relay (Single Point program only). Process medium is conductive, but non-conductive was chosen in step 2 of Single Point program. Recalibrate steps 2 and 3 of Single Point program with accurate information. Display reads UNDR. Numbers have exceeded lower limit of negative 999, usually caused by PRLO/ PRHI points being entered extremely close to (or on top of) one another. Recalibrate PRLO/PRHI points. Display reads OVER. Numbers have exceeded upper limit of 19,999, usually caused by PRLO/ PRHI points being entered extremely close to (or on top of) one another. Recalibrate PRLO/PRHI points. No fail-safe choice offered for RLY 3 LEAD is chosen in Mode/Control, yielding a lead-lag function. This is a normal condition for the lead-lag function. Error messages 11, 12, 16 25 AC/DC DC Consult factory. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 3.2 Specifications 3.2.1 Electrical Supply voltage 120 VAC, 50/60 Hz (+10/-15%) 240 VAC, 50/60 Hz (+10/-15%) 24 VDC (±10%) 15 VA nominal 99% non-condensing (electronics) Per IEC specification 801-2 70 ms to approximately 2 seconds, depending upon probe capacitance and averaging value -40° F to +160° F (-40° to +70° C) ±0.01%/degree F (±0.018%/degree C) Power consumption Humidity Electrostatic discharge protection Response time Ambient temperature Temperature coefficient of set point Maximum remote mount distance Standard Intrinsically safe 2500 feet (760 m) 800 feet (240 m) Data Entry Indication 3-button keypad 4-digit LED, 1 overflow LED for +10,000 Relays 2 to 4 DPDT AC DC Set point range Differential range Time delay 10 amp @ 120/240 VAC resistive 10 amp @ 30 VDC resistive, 0.5 amp @ 125 VDC resistive 0–50,000 pF 0.50 pF minimum / 50,000 pF maximum 0–90 seconds level rising, falling, both 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 26 3.3 Agency Approvals Agency Approved Model Protection Method Area Classification FM 8X2-1X02-G0X 8X2-1X03-G0X with rigid insulated probe Explosion proof Class I Div. 1, Groups C & D Class II Div. 1, Groups E, F & G NEMA 4X, IP65 8X2-1X05-G0X 8X2-1X06-G0X Explosion proof with intrinsically safe probe circuit Electronics: Class I Div. 1, Groups C & D Class II Div. 1, Groups E, F & G NEMA 4X, IP65 Probe: Class I, II, III, Div. 1, Groups A, B, C, D, E, F & G NEMA 4X, IP65 8X2-1X02-R0X 8X2-1X03-R0X 8X2-1X03-Y0X with rigid insulated probe Explosion proof Class I Div. 1, Groups B, C & D Class II Div. 1, Groups E, F & G NEMA 4X, IP65 8X2-1X05-R0X 8X2-1X06-R0X 8X2-1X06-Y0X Explosion proof with intrinsically safe probe circuit Electronics: Class I, Div. 1, Groups B, C & D Class II, Div. 1, Groups E, F & G NEMA 4X, IP65 Probe: Class I, II, III, Div. 1, Groups A, B, C, D, E, F & G NEMA 4X, IP65 CSA 8X2-1X00-C00 8X2-1X01-C00 Non-hazardous TYPE 4X 8X2-1X02-G0X 8X2-1X03-G0X with rigid insulated probe Explosion proof Class I Div. 1, Groups C & D Class II Div. 1, Groups E, F & G TYPE 4X 8X2-1X05-G0X 8X2-1X06-G0X Explosion proof with intrinsically safe probe circuit Electronics: Class I Div. 1, Groups C & D Class II Div. 1, Groups E, F, G TYPE 4X Probe: Class I, II, III, Div. 1, Groups A, B, C, D, E, F & G TYPE 4X 8X2-1X02-R0X 8X2-1X03-R0X 8X2-1X03-Y0X with rigid insulated probe Explosion proof Class I Div. 1, Groups B, C & D Class II Div. 1, Groups E, F & G TYPE 4X 8X2-1XX5-R0X 8X2-1XX6-R0X 8X2-1XX6-Y0X Explosion proof with intrinsically safe probe circuit Electronics: Class I Div. 1, Groups B, C & D Class II Div. 1, Groups E, F, G TYPE 4X Probe: Class I, II, III, Div. 1, Groups A, B, C, D, E, F & G TYPE 4X 27 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 3.4 Intrinsic Safety 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 28 3.4 Intrinsic Safety (cont.) Amplifier Amplifier Potted intrinsically safe module Potted intrinsically safe module Potted preamplifier module – Terminal + Terminal + Terminal – Terminal To Remote – Pre-amplifier + Front View Front View Power supply/relays Power supply/relays Amplifier Amplifier Potted intrinsically safe module Potted intrinsically safe module Potted preamplifier module Side View Side View Figure 15 Model 8X2-1X06-G0X Remote Mount Intrinsically Safe Probe Circuit Explosion Proof Housing Figure 16 Model 8X2-1X05-G0X Integral Mount Intrinsically Safe Probe Circuit Explosion Proof Housing Potted preamplifier module Potted intrinsically safe module Guard wire (red) if needed Probe Probe wire (white) Figure 17 29 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 3.5 Specifications 3.5.1 Dimensional inches (mm) clearance 4.63 (118) Dia. 3.00 (76) B B 1 Rotation 1 Rotation A A clearance 2.75 (70) E 3.75 (95) C G 3/4" NPT G G G plugged plugged D 2.37 (60) 2 Holes .38 (10) Dia. F 2 3.00 (76) 2.00 (51) 1/2" NPT or 3/4" NPT 2 3.50 (89) Optional mounting flange Optional mounting flange 4.11 (104) IL 3 IL .375 (10) Figure 19 Remote Mount with Guarded Probe (shown with Aluminum Housing) .375 (10) Figure 18 Integral Mount with Guarded Probe (shown with Aluminum Housing) Outline Dimensions Standard Rigid Probe Housing Flexible Probe Guarded Probe A B C D E F C D E F C D E F NEMA 4X Carbon steel 3.25 (82) 4.69 (119) 9.04 (230) 2.29 (58) 11.67 (296) 4.04 (103) 10.48 (266) 3.73 (95) 11.67 (296) 4.04 (103) 9.84 (250) 3.17 (80) 11.67 (296) 4.04 (103) NEMA 4X/7/9 Cast iron 5.25 (133) 5.81 (148) 11.26 (286) 2.40 (61) 13.81 (351) 4.15 (105) 12.70 (323) 4.67 (119) 13.81 (351) 4.15 (105) 12.06 (306) 3.28 (83) 13.81 (351) 4.15 (105) NEMA 4X/7/9 Aluminum 3.87 (98) 5.93 (151) 10.89 (276) 2.44 (61) 13.44 (341) 4.11 (104) 12.33 (313) 4.71 (119) 13.44 (341) 4.11 (104) 11.69 (296) 3.32 (84) 13.44 (341) 4.11 (104) 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 30 inches (mm) 1 Rotation clearance B B 1 Rotation clearance A C A C G G D D 2 2 IL IL .50 (13) .625 (16) .50 (13) .625 (16) Figure 21 Integral Mount with Flexible Probe (shown with Cast Iron Housing) Figure 20 Integral Mount with Standard Rigid Probe (shown with Carbon Steel Housing) 4.63 (118) Dia. B 1 Rotation clearance 3.00 (76) A 2.75 (70) E 3.75 (95) 3/4" NPT G Optional mounting flange 3.23 (82) 2.37 (60) 2 Holes .38 (10) Dia. 2 F 3.00 (76) 2.00 (51) 1/2" NPT or 3/4" NPT 3.50 (89) IL 3 .50 (13) .625 (16) Figure 22 Remote Mount with Standard Rigid Probe (shown with Carbon Steel Housing) 31 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches inches (mm) 4.63 (118) Dia. B 1 Rotation clearance A 3.00 (76) 2.75 (70) E 3.75 (95) 3/4" NPT 2 Holes .38 (10) Dia. Optional mounting flange 4.67 (119) G 2.37 (60) F 2 3.00 (76) 2.00 (51) 3.50 (89) .1875 (5) .2500 (6) 1/2" NPT or 3/4" NPT 2.95 (75) 3 4.87 (124) 1.25 (32) Optional anchor assembly (P/N 032-8902-001) 5.55 (141) .75 (19) Optional weight (P/N 004-4355-001) Figure 23 Remote Mount with Flexible Probe (electronic shown with Cast Iron Housing) Conduit Connections G NEMA 4X Single conduit 3 NEMA 4X/7/9 Single conduit 1" NPT NEMA 4X/7/9 Dual conduit 1" NPT ⁄ 4" NPT NOTES: Allow 8 in. (203 mm) overhead clearance for cover removal. Standard process connection is 3⁄4" NPT. Consult probe brochure (50-125) for flange and other probe connections. Probe/amplifier connecting cable to be shielded, twisted-pair, 22-gauge stranded conductors. Magnetrol P/N 009-7146-001 2500 feet (760 m); maximum 800 feet (240 m) maximum for intrinsically safe models. 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 32 3.6 Parts 3.6.1 Replacement No. Description Part Number Non-hazardous Z30-2409-001 Hazardous Z30-2409-001 Amplifier I.S. circuitry Z30-2410-001 1 Non-hazardous Z30-2410-002 PC board Remote Hazardous Z30-2410-002 I.S. circuitry Z30-2410-001 Note: Refer to model number digit 7 for proper amplifier PC board Power supply/relay board: Model 822 Model 832 Model 842 120 VAC Z30-2407-001 Z30-2407-002 Z30-2407-003 2 240 VAC Z30-2407-004 Z30-2407-005 Z30-2407-006 24 VDC Z30-2407-007 Z30-2407-008 Z30-2407-009 Preamplifier board: A. Standard (remote) Z30-2411-002 3 B. Intrinsically safe, remote (potted module) Z30-9005-001 C. Intrinsically safe, integral (potted module) Z30-9003-001 4 Intrinsically safe barrier (potted module) Z30-9002-001 NEMA 4X Carbon steel 089-6523-001 5 Housing NEMA 4X/7/9 Cast iron 089-6554-002 cover NEMA 4X/7/9 Aluminum 089-6554-003 NEMA 4X 012-1318-001 6 O-Ring NEMA 4X/7/9 012-2501-249 NEMA 4X Aluminum 004-9165-002 single conduit Housing NEMA 4X/7/9 Cast iron, 7 base 004-9138-003 single conduit NEMA 4X/7/9 Aluminum 004-9173-003 dual conduit 1 2 Integral 8 9 10 33 Remote probe housing Aluminum single conduit 316 SS, single conduit 4 3C 6 7 9 10 3A 3B 089-6585-001 089-6585-002 1 ⁄ 2" NPT 3 ⁄ 4" NPT Connecting cable up to 2500 ft. (760 m) Intrinsically safe 800 ft. (240 m) (shielded, twisted pair, 22-gauge stranded conductors) Remote electronics mounting bracket 5 036-3805-001 036-3805-003 8 009-7146-001 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 3.7 Model Numbers RELAYS 2 3 4 Relays 3 Relays (lead/lag) 4 Relays (lead/lag) INPUT POWER 0 120 VAC 1 240 VAC 2 24 VDC MOUNTING 0 Integral NEMA 4X 1 Remote NEMA 4X 2 Integral NEMA 4X/7/9 3 Remote NEMA 4X/7/9 5 Integral NEMA 4X/7/9 w/intrinsically safe probe circuit 6 Remote NEMA 4X/7/9 w/intrinsically safe probe circuit HOUSINGS C G R Y NEMA 4X, aluminum base with carbon steel cover, 3 ⁄4" NPT single conduit NEMA 4X/7/9, cast iron, 1" NPT single conduit NEMA 4X/7/9, aluminum, 1" NPT dual conduit NEMA 4X/7/9, aluminum, 1" NPT dual conduit with 316 SS 3⁄4" NPT single conduit (remote mount only) PROBE SELECTION 8 2 1 0 0 Probe ordered separately 1 18" (457 mm) guarded probe) 2 36" (914 mm) guarded probe) 0 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 34 NOTES 35 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches NOTES 50-621 Kotron Sentinel Models 822, 832 and 842 RF Point Level Switches 36 ASSURED QUALITY & SERVICE COST LESS Service Policy Return Material Procedure Owners of Magnetrol controls may request the return of a control or any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Controls returned under our service policy must be returned by Prepaid transportation. Magnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior to the material's return. This is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor and the parts required to rebuild or replace the equipment. In some cases it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned will be determined on the basis of the applicability of our warranty. No claims for misapplication, labor, direct or consequential damage will be allowed. 1. 2. 3. 4. 5. Company Name Description of Material Serial Number Reason for Return Application Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F.O.B. factory. NOTE: See Electrostatic Discharge Handling Procedure on page 1. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4028 • Fax 630-969-9489 • www.sticontrols.com Copyright © 2006 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. CSA logotype is a registered trademark of Canadian Standards Association Mylar® is a registered trademark of DuPont Teijin Films Teflon® is a registered trademark of DuPont Performance Elastomers BULLETIN: 50-621.9 EFFECTIVE: September 2005 SUPERSEDES: July 2004